Electrical connector for illuminated panel



March 19, 1963 3,082,395

L. E. MADANSKY ELECTRICAL CONNECTOR FOR ILLUMINATED PANEL Filed June 15,1961 rates Pate Leslie E. Madanslry, Burbank, Calif, assignor toCalifornia lflasteek, inc, Los Angeles, Calif, a corporation ofCalifornia Filed .l'nne I3, 1961, Ser. No. 116,726 5 Claims. (Cl.339-17) This invention relates to an illuminated panel of the typecommonly used on aircraft. Such a panel is of laminar construction witha thick main layer of transparent plastic and with an outer opaque layeron both faces of the panel. Commonly a translucent layer underlies eachof the two outer opaque layers. The opaque layer on the front face ofthe panel has indicia cut-outs which are illuminated by edge lighting,i.e. by light transmitted through the main transparent layer edgewisethereof from one or more lamps mounted in the plane of the main layer.Typically the circuit conductors for energizing the lamps are locatedbetween l-aminations of the panel.

The invention is directed to means for connecting the lamps of the panelwith an source and, more particularly, relates to a connector means onthe panel for plugging into a complementary connector means from thesource. The problem is to provide a connector means that is efiicientfor its purpose, that is well insulated to avoid shorts, and, inaddition, is of relatively shnple and inexpensive structure.

The invention is characterized by the concept of meeting these problemsby incorporating a plug-in connector into the structure of the panelitself so that the connector lies largely inside the panel and is, ineffect, integral with the panel. In such a construction, the plug-inconnector is largely protected by the panel itself and derives strengthand durability from the'panel itself. A further advantage is the savingof space since the major portion of the plug-in connector is in thespace occupied by the panel with only a minimum portion of the connectornecessarily protruding from the panel.

In the preferred practice of the invention, this concept is carried outby drilling three blind bores into one face of the panel, usually theback face. One blind bore is relatively deep and of relatively largediameter. The other two blind bores are of less depth and less diameterand overlap the deeper bore to open laterally into the deeper bore. Thetwo circuit conductors of the panel are then extended into the tworelatively-shallow blind bores respectively.

An insulating plastic body dimensioned to fill the large bore is moldedwith two one-piece metal connector conductor bodies partially embeddedtherein, the two conductor bodies being spaced apart by the material ofthe plastic body for insulation from each other. The two conductorbodies have respectively exposed plug-in portions extending outward fromone end of the plastic body and the two conductor bodies also haverespective portions extending radially from the plastic body.

The molded plastic body is inserted into the large blind bore and bondedin place with the two radial portions of the two conductor bodiesextending into the adjacent shallow blind bores, respectively, incontact with the corresponding extended circuit conductors therein.Finally, the two shallow blind bores and the radial portions of theconductor bodies therein are covered with a layer of insulatingmaterial.

The invention may be fully understood from the following detaileddescription and the accompanying drawing.

In the drawing, lustrative:

which is to be regarded as merely il- FIG. 1 is a perspective view of anunfinished portion of an illuminated panel with the three blind bores inthe rear face thereof and with the presently preferred embodiment of theconnector poised for installation in the three blind bores;

FIG. 2 is an enlarged fragmentary plan view of the. completed panel withthe connector seated in the three blind bores;

FIG. 3 is a transverse section taken as indicated by the line 33 of FIG.2; and

FIG. 4 is a transverse section taken as indicated by the line 44 of FIG.3.

The selected embodiment of the invention is incorporated in anedge-lighted panel, generally designated P. The panel P is of laminarplastic construction having a relatively thick main layer 10 of clearplastic. The front face of the panel P is covered with an opaque plasticlayer 12 and a translucent layer 14 is interposed between the main layerand the opaque layer. The opaque layer 12 has cut-outs therein (notshown) forming indicia and other design elements which are illuminatedfrom the interior of the panel. The back face of the panel has atranslucent layer 15 bonded to the main transparent layer 10 for thepurpose of reflecting light internally of the panel and the translucentlayer 15 is covered with an opaq'ue layer 16 which forms the back faceof the panel.

The circuit conductors carried by the panel for energizing the lamps inthe panel may be provided in any suitable manner. In the constructionshown, two printed circuit conductor-s 18 and 20 are interposed betweenthe rear translucent layer 15 and the rear opaque layer 16, the printedcircuit conductors being depressed into the material of the maintranslucent layer 10.

In accord with the teachings of the invention, a relatively deep blindbore 22 of relatively large diameter i formed in the back face of thepanel and extends into the clear lamination 1t). Adjacent the deep blindbore 22 on diametrically opposite sides thereof are two shallow blindbores 24 and 25 of lesser diameter which, as best shown in F1G.,l,overlap the blind bore and open laterally into the interior of the blindbore. The two shallow blind bores 24 and 25 intersect the two printedcircuit conductor-s 18 and 20 and the two printed circuit conductors areextended into the two shallow recesses onto the bottom surface thereofas indicated at 18a and 20a in FIG. 3. In the fabrication of the panelthe two printed circuit conductors 18 and 20 may be applied to the mainclear plastic layer 10 and embedded therein under pressure and then thecircuit conductor extensions 18a and Zlla may be formed in therespective shallow recesses before the translucent layer 14 and the opaqe layer 12 are added. The extensions 18a and 20a of the two printedcircuit conductors 18 and 20 into the two shallow recesses 24 and 25respectively may be made after the printed circuit conductors arepressed into the main clear layer 10 and before the translucent layer 14and the opaque layer 12 are added.

A solid plastic body 26 of non-conducting material substantially fillsthe relatively large and relatively deep blind bore 22. Preferably theplastic body is dimensioned to be substantially flush with the back faceof the panel as shown in FIGS. 3 and 4. Partially embedded in theplastic body 26 is a first one-piece metal connector conductor bodygenerally designated 28 and a second onepiece connector conductor bodygenerally designated 30.

The first conductor body 28 has a base portion 32 (FIG. v3) having theconfiguration of a segment of a ring, the ring having a gap formed bytwo ends 34 indicated in dotted lines in FIG. 2. Diametrically oppositefrom the gap, the ring-shaped base portion 32 has a radial extension inthe form of a tongue 35. When the plastic body 26 is bonded in itsassembled position as shown in FIGS. 2, 3 and 4, the tongue 35 fits intothe shallow blind bore 24. The tongue conforms to the shallow recess in.

plan and overlies the circuit conductor 18a in the recess. Both thering-shaped base portion 32 and the radial portion or tongue 35 arespaced inward from the outer end of the plastic body 26 so that both arecovered and protected by a layer of the material of the plastic body.The first conductor body 28 is further formed with a thinwalledcylindrical plug-in portion 36 which extends outward from the outer endof the plastic body 26 and outward from the plane of the rear face ofthe panel P. The cylindrical portion 36 is concentric of the baseportion 32 and in this instance has the same inside diameter.

The second conductor body 30 has an exposed prong portion 38 whichextends outward from the plastic body inside the cylindrical portion 36of the first conductor body and preferably concentrically thereof. Thesecond conductor body 30 has a base portion 40 (FIG. 3) which extendsradially of the prong portion 38 and this base portion 40 has a thinnerradial extension 42 in the form of a tongue. Both the base portion 40and the radial extension 42 are spaced inward from the outer end of theplastic body 26 to be covered and protected by a layer of the materialof the plastic body. The radially extending portion of the secondconductor body 30 which comprises the base portion 40 and the radialtongue 42, extends through the gap between the two ends 34 of thering-shaped base portion 42 of the first connector conductor 28, and thecylindrical portion 36 of the first connector conductor is cut away orrecessed to provide a liberal clearance between the two conductor bodiesin this region. The two conductor bodies are insulated from each otherin the region of the gap by the material of the plastic body 26. Whenthe plastic body 26 is installed in the larger blind bore 22 of thepanel the radial tongue 42 extends into the second shallow blind bore25. The radial tongue 42 conforms to the configuration in plan of theshallow blind bore 25 and is in overlying contact with the circuitconductor 29a therein.

It is contemplated that the two radial portions or tongues and 42 of thetwo conductor bodies 28 and 30 respectively will be covered with a layerof suitable insulating material. In this particular practice of theinvention an insulating ring 44 of thin plastic material covers the twotongues 35 and 42, the plastic ring being adhesively bonded to the outersurfaces of the two tongues and being also adhesively bonded to theadjacent annular region of the back face of the panel P. The plasticring 44 may, for example, be made of a vinyl resin.

It is apparent that the two plug-in portions of the two conductorbodies, which plug-in portions comprise the cylindrical portion 36 andthe prong portion 38 are adapted to cooperate with a complementaryelectrical connector means. The complementary electrical connector means(not shown) is of the well known type having an axial socket to receivethe prong 38 and an annular socket to receive the cylindrical portion36, both sockets having conductors exposed therein to carry current froman E.M.F. source. Preferably the cylindrical wall portion 36 of thefirst conductor body 30 is longitudinally split or slotted forflexibility. In the construction shown the cylindrical portion 36 hastwo relatively deep longitudinal slots 45 which extend inward from itsouter edge.

In an initial practice of the invention the plugin connector isrelatively small, the diameter of the plastic body 26 and the deep blindbore 22 in which it is mounted being approximately /3. The diameter ofthe two shallow blind bores 24 and 25 is at least on the order ofone-half of the diameter of the deeper bore. In this instance, thediameter of the two shallower bores is A" or two-thirds of the diameterof the deeper bore. 1 t

The described plug-in connector is of rugged durable construction initself and when it is installed it gains strength from reinforcement bythe panel. The ruggedness of the connector is increased by therelatively large areas of the two radial tongues 35 and 42 lying snuglyagainst corresponding areas of the corresponding shallow bores. Theplastic body cooperates with the two metal connector bodies 28 and 30 byboth supporting the two connector bodies and by insulating the twoconductor bodies from each other. The radial projection of the secondconnector body 31] is of small cross section at its root as may be seenin FIG. 2, but it is relatively thick vertically as may be seen in FIG.3, and is amply reinforced by the solid plastic body.

The manner in which the invention serves its purpose may be readilyunder-stood from the foregoing description. It is an exceedingly simplematter to drill the blind bores 22, 24 and 25 in the panel P, the largerdeeper blind bore 22 being drilled last. The plastic body 26 may bebonded in place by means of a suitable adhesive that is cured by heat.In the preferred practice of the invention, the plastic body is mountedin the panel by means of uncured epoxy potting resin before the outeropaque layer 12 is cured and then the whole panel is heated to cure boththe outer opaque plastic layer and the potting resin. After this curingoperation, the plastic ring 44 which is shown in phantom in FIGS. 2, 3,and 4 is assembled to the panel.

My description in specific detail of the preferred practice ofi theinvention will suggest various changes, substitutions and otherdepartures from my disclosure within the spirt and scope of the appendedclaims.

I claim:

1. A combination for plugging into an source comprising: an edge-lightedpanel having a relatively deep recess in one face of the panel and tworelatively shallow recesses adjacent said deep recess in communicationtherewith; two spaced circuit conductors on the panel for energizing alamp means on said panel, said conductors extending into said recesses,respectively; an insulating plastic body substantially filling said deeprecess and anchored therein; a first one-piece metal connector conductorbody partially embedded in said plastic body, said conductor body havingan exposed generally cylindrical portion extending outward from saidface of the panel and having a radial portion protruding from theplastic body into one of said shallow recesses in contact with thecorresponding circuit conductor therein; and a second one-piece metalconnector conductor body partially embedded in said plastic body inspaced relation to the first conductor body, said second conductor bodyhaving an exposed prong portion extending outward from said face of thepanel inside said cylindrical portion of the first conductor body, saidsecond conductor body having a radial portion protruding from theplastic body into the other of said shallow recesses in contact with thecorresponding circuit conductor therein; said first conductor body beingrecessed to clear said radial portion of the second connector conductorin spaced relation thereto.

2. A combination for plugging into an source comprising: an edge-lightedpanel having in one of its faces a relatively deep recess and tworelatively shallow recesses adjacent the deep recess in communicationtherewith; two spaced circuit conductors between larninations of thepanel for energizing a lamp rnbans on said panel, said conductorsextending into said two shallow bores respectively and overlying thebottom. surfaces of the shallow bores; an insulating plastic bodysubstantially filling said deep bore and anchored therein; a firstone-piece connector conductor body partially embedded in said plasticbody, said conductor body having an exposed plug-in portion. extendingoutward from said face of the panel and having a radial portionprotruding from the plastic body into one of said shallow bores incontact with the corresponding circuit conductor therein; a secondone-piece metal connector conductor body partially embedded in saidplastic body in spaced relation to the first conductor body, said secondconductor body having an exposed plug-in portion extending outward fromsaid face of the panel, said second conductor body having a radialportion protruding from the plastic body into the other of said shallowbores in contact with the corresponding circuit conductor therein; and alayer of insulating material overlying said radial portions of the twoconductor bodies.

3. A combination as set forth in claim 2 in which the diameter of eachof said shallow blind bores is more than half the diameter of the deepbore; and in which said radial portions of the two conductor bodiesconform with the two shallow blind bores to fill the shallow bores asviewed in plan.

'4. A combination as set forth in claim} 2 in which one of said plug-inportions of the two conductor bodies is of thin walled cylindricalconfiguration and is longitudinally slotted.

5. A combination for plugging into an source comprising: an edge-lightedpanel having in its back face a relatively deep blind bore and tworelatively shallow blind bores adjacent the deep bore and overlappingthe deep bore for communication therewith; two spaced circuit conductorson the panel for energizing a lamp means on said panel, said conductorsextending into said shallow bores respectively and overlying the bottomfaces of the shallow bores; an insulating plastic body substantiallyfilling said deep bore substantially flush with the back face of thepanel, said plastic body, being anchored to the panel; a first connectorconductor body partially embedded in said plastic body; said conductorbody having a base portion of the shape of a segment of a ring with agap between the two ends of the ring, said conductor body having anexposed generally cylindrical plug-in portion extending outward from theouter end of the plastic body, said conductor body further having aradial portion extending from said base portion into one of saidrecesses in overlapping contact with the corresponding cirouit conductortherein; a second connector conductor body partially embedded in saidbody in spaced relation to said first conductor body, said secondconductor body having an exposed plug-in prong portion extending outwardfirom the outer end of the plastic body inside said cylindrical portionof the first conductor body, said second conductor body having a radialportion extending through said gap in the ring-shaped base portion ofthe first conductor body, said radial portion of the second connectorconductor extending into the other of said two shallow bores inoverlapping contact with the cor-responding circuit conductor therein,said base portion and said radial portion of the first conductor bodyand said radial portion of the second conductor body being spacedinwardly from the outer end of the plastic body; and insulating materialextending over said shallow bores and covering said radial portions ofthe two conductor bodies.

Dods Mar. 1, 1910 Appel June 11, 1929 Peak et al. June 6, 1961

1. A COMBINATION FOR PLUGGING INTO AN E.M.F. SOURCE COMPRISING: ANEDGE-LIGHTED PANEL HAVING A RELATIVELY DEEP RECESS IN ONE FACE OF THEPANEL AND TWO RELATIVELY SHALLOW RECESSES ADJACENT SAID DEEP RECESS INCOMMUNICATION THEREWITH; TWO SPACED CIRCUIT CONDUCTORS ON THE PANEL FORENERGIZING A LAMP MEANS ON SAID PANEL, SAID CONDUCTORS EXTENDING INTOSAID RECESSES, RESPECTIVELY; AN INSULATING PLASTIC BODY SUBSTANTIALLYFILLING SAID DEEP RECESS AND ANCHORED THEREIN; A FIRST ONE-PIECE METALCONNECTOR CONDUCTOR BODY PARTIALLY EMBEDDED IN SAID PLASTIC BODY, SAIDCONDUCTOR BODY HAVING AN EXPOSED GENERALLY CYLINDRICAL PORTION EXTENDINGOUTWARD FROM SAID FACE OF THE PANEL AND HAVING A RADIAL PORTIONPROTUDING FROM THE PLASTIC BODY INTO ONE OF SAID SHALLOW RECESSES INCONTACT WITH THE CORRESPONDING CIRCUIT CONDUCTOR THEREIN; AND A SECONDONE-PIECE METAL CONNECTOR CONDUCTOR BODY PARTIALLY EMBEDDED IN SAIDPLASTIC BODY IN SPACED RELATION TO THE FIRST CONDUCTOR BODY, SAID SECONDCONDUCTOR BODY HAVING AN EXPOSED PRONG PORTION EXTENDING OUTWARD FROMSAID FACE OF THE PANEL INSIDE SAID CYLINDRICAL PORTION OF THE FIRSTCONDUCTOR BODY, SAID SECOND CONDUCTOR BODY HAVING A RADIAL PORTIONPROTRUDING FROM THE PLASTIC BODY INTO THE OTHER OF SAID SHALLOW RECESSESIN CONTACT WITH THE CORRESPONDING CIRCUIT CONDUCTOR THEREIN; SAID FIRSTCONDUCTOR BODY BEING RECESSED TO CLEAR SAID RADIAL PORTION OF THE SECONDCONNECTOR CONDUCTOR IN SPACED RELATION THERETO.